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A summary of the mechanical design of the boiler plate nacelle for the QCSEE over the wing (OTW) engine is presented. The nacelle, which features a D-shaped nozzle/thrust reverser and interchangeable hard wall and acoustic panels, is utilized in the engine testing to establish the aerodynamic and acoustic requirements for nozzles and reversers of this type.
The element and subcomponent testing conducted to verify the under the wing composite nacelle design is reported. This composite nacelle consists of an inlet, outer cowl doors, inner cowl doors, and a variable fan nozzle. The element tests provided the mechanical properties used in the nacelle design. The subcomponent tests verified that the critical panel and joint areas of the nacelle had adequate structural integrity.
Detailed design parameters are presented for a variable-pitch change mechanism. The mechanism is a mechanical system containing a ball screw/spline driving two counteracting master bevel gears meshing pinion gears attached to each of 18 fan blades.
Sets of under the wing (UTW) engine reduction gears and sets of over the wing (OTW) engine reduction gears were fabricated for rig testing and subsequent installation in engines. The UTW engine reduction gears which have a ratio of 2.465:1 and a design rating of 9712 kW at 3157 rpm fan speed were operated at up to 105% speed at 60% torque and 100% speed at 125% torque. The OTW engine reduction gears which have a ratio of 2.062:1 and a design rating of 12,615 kW at 3861 rpm fan speed were operated at up to 95% speed at 50% torque and 80% speed at 109% torque. Satisfactory operation was demonstrated at powers up to 12,172 kW, mechanical efficiency up to 99.1% UTW, and a maximum gear pitch line velocity of 112 m/s (22,300 fpm) with a corresponding star gear spherical roller bearing DN of 850,00 OTW. Oil and star gear bearing temperatures, oil churning, heat rejection, and vibratory characteristics were acceptable for engine installation.
The viability of proposed bearing designs to operate at application conditions is described. Heat rejection variables were defined for the test conditions. Results indicate that there is potential for satisfactory operation of spherical roller bearing in the QCSEE main reduction gear application.
Lightweight turbine engines with geared slower speed fans are considered. The design of two similar but different gear ratio, minimum weight, epicyclic star configuration main reduction gears for the under the wing (UTW) and over the wing (OTW) engines is discussed. The UTW engine reduction gear has a ratio of 2.465:1 and a 100% power design rating of 9885 kW (13,256 hp) at 3143 rpm fan speed. The OTW engine reduction gear has a ratio of 2.062:1 and a 100% power design rating of 12813 kW (17183 hp) at 3861 rpm fan speed. Details of configuration, stresses, deflections, and lubrication are presented.
A variable pitch fan actuation system was designed which incorporates a remote nacelle-mounted blade angle regulator. The regulator drives a rotating fan-mounted mechanical actuator through a flexible shaft and differential gear train. The actuator incorporates a high ratio harmonic drive attached to a multitrack spherical cam which changes blade pitch through individual cam follower arms attached to each blade trunnion. Detail design parameters of the actuation system are presented. These include the following: design philosophies, operating limits, mechanical, hydraulic and thermal characteristics, mechanical efficiencies, materials, weights, lubrication, stress analyses, reliability and failure analyses.
The design, fabrication, and testing of two experimental high bypass geared turbofan engines and propulsion systems for short haul passenger aircraft are described. The aerodynamic and mechanical design of a variable pitch 1.34 pressure ratio fan for the under the wing (UTW) engine are included. The UTW fan was designed to permit rotation of the 18 composite fan blades into the reverse thrust mode of operation through both flat pitch and stall pitch directions.
An advanced composite frame which is flight-weight and integrates the functions of several structures was developed for the over the wing (OTW) engine and for the under the wing (UTW) engine. The composite material system selected as the basic material for the frame is Type AS graphite fiber in a Hercules 3501 epoxy resin matrix. The frame was analyzed using a finite element digital computer program. This program was used in an iterative fashion to arrive at practical thicknesses and ply orientations to achieve a final design that met all strength and stiffness requirements for critical conditions. Using this information, the detail design of each of the individual parts of the frame was completed and released. On the basis of these designs, the required tooling was designed to fabricate the various component parts of the frame. To verify the structural integrity of the critical joint areas, a full-scale test was conducted on the frame before engine testing. The testing of the frame established critical spring constants and subjected the frame to three critical load cases. The successful static load test was followed by 153 and 58 hours respectively of successful running on the UTW and OTW engines.
High bypass geared turbofan engines and propulsion systems designed for short-haul passenger aircraft are described. The propulsion technology required for future externally blown flap aircraft with engines located both under the wing and over the wing is emphasized. The aerodynamic and mechanical preliminary design of the QCSEE under the wing 1.34 pressure ratio fan with variable blade pitch is presented. Design information is given for two pitch change actuation systems which will provide reverse thrust.
The aerodynamic and mechanical preliminary design of the QCSEE over the wing 1.36 pressure ratio fan is presented. Design information is given for both the experimental and flight designs.
The design and analysis of a composite fan blade for the under the wing (UTW) QCSEE is presented. The blade is designed for a variable pitch, 18 bladed rotor and is constructed from a hybrid composite combination of materials consisting of Kevlar-49, type AS graphite, boron, and S-glass fibers in a PR288 epoxy resin matrix. The blade has an attached platform which is constructed of AS-graphite, PR288 epoxy resin matrix and aluminum honeycomb. The blade is designed to satisfy aerostability and cyclic life and strength requirements with a light weight construction. The attached platform is designed for a fail-safe condition in that it is retainable by the blade, under centrifugal force loading, even in the event of blade to platform bond separation. Details of the blade design and the results of stress, vibration, and impact analysis are included.
A hybrid-computer simulation of the over the wing turbofan engine was constructed to develop the dynamic design of the control. This engine and control system includes a full authority digital electronic control using compressor stator reset to achieve fast thrust response and a modified Kalman filter to correct for sensor failures. Fast thrust response for powered-lift operations and accurate, fast responding, steady state control of the engine is provided. Simulation results for throttle bursts from 62 to 100 percent takeoff thrust predict that the engine will accelerate from 62 to 95 percent takeoff thrust in one second.
The component testing of a ball spline variable pitch mechanism is described including a whirligig test. The variable pitch actuator successfully completed all planned whirligig tests including a fifty cycle endurance test at actuation rates up to 125 deg per second at up to 102 percent fan speed (3400 rpm).
The mechanical design of the boiler plate nacelle and core exhaust nozzle for the QCSEE under the wing engine is presented. The nacelle, which features interchangeable hard-wall and acoustic panels, is to be utilized in the initial engine testing to establish acoustic requirements for the subsequent composite nacelle as well as in the QCSEE over the wing engine configuration.
A variable pitch fan actuation system, which incorporates a remote nacelle mounted blade angle regulator, was tested. The regulator drives a rotating fan mounted mechanical actuator through a flexible shaft and differential gear train. The actuator incorporates a high ratio harmonic drive attached to a multitrack spherical cam which changes blade pitch through individual cam follower arms attached to each blade trunnion. Testing of the actuator on a whirl rig, is reported. Results of tests conducted to verify that the unit satisfied the design requirements and was structurally adequate for use in an engine test are presented.
A series of acoustic tests were conducted on the over the wing engine. These tests evaluated the fully suppressed noise levels in forward and reverse thrust operation and provided insight into the component noise sources of the engine plus the suppression achieved by various components. System noise levels using the contract specified calculation procedure indicate that the in-flight noise level on a 152 m sideline at takeoff and approach are 97.2 and 94.6 EPNdB, respectively, compared to a goal of 95.0 EPNdB. In reverse thrust, the system noise level was 106.1 PNdB compared to a goal of 100 PNdB. Baseline source noise levels agreed very well with pretest predictions. Inlet-radiated noise suppression of 14 PNdB was demonstrated with the high throat Mach number inlet at 0.79 throat Mach number.
The detail design of the under the wing experimental composite nacelle components is summarized. Analysis of an inlet, fan bypass duct doors, core cowl doors, and variable fan nozzle are given. The required technology to meet propulsion system performance, weight, and operational characteristics is discussed. The materials, design, and fabrication technology for quiet propulsion systems which will yield installed thrust to weight ratios greater than 3.5 to 1 are described.